North Star 27500 User's Manual
Contents
1. 0810 A Bearing The bearings used in this generator are a heavy duty sealed ball bearing type They require no maintenance or lubtication B Receptacles Quality receptacles have been utilized If a receptacle should become cracked or otherwise damaged replace it Using cracked or damaged receptacles can be both dangerous to the operator and destructive to the equipment WARNING Stand by Operation If your generator is to be used as a standby electric power source in case of utility failure it must be installed by a registered and licensed electrician and in compliance with all applicable state and local electrical codes Also local Fire Departments must be consulted concerning proper and safe handling procedures for gasoline NEVER connect any generator to any existing electrical system without an isolating UL approved transfer switch installed by a licensed electrician TROUBLESHOOTING Problem Voltage too low Circuit breaker trips Voltage too high Generator overheating No output voltage Excessive gear box noise Possible Causes Engine speed too slow Generator is overoaded Defective load connected to generator Defective receptace Generator overnoaded Defective circuit breaker Engine speed too high Generator is overloaded Insufficient ventilation Defective load connected to generator Broken orloose wire Defective receptade Defective stator Defective rotor De2. thatis driven into moist soil Reference 16 100A Circuit Breaker One 100A thermal magnetic breaker Reference 17 120 240V 100A Pin and Sleeve This extremely safe and durable receptacle can be used for all large loads induding transfer switches IEC 309 1 number 4100R12W A plug part 32802 can be ordered from NorthStar at 1 800 270 0810 Reference 18 60A Circuit Breaker One 60A thermal magnetic breaker References 11 Shield Plastic implement shield NEVER operate generator without shield in place INTRODUCTION Before attempting to mount your generator thoroughly study the instructions and cautions in this manual to assure you are fully acquainted with the operation of all components of this generator Proper preparation operation and maintenance will result in operator safety best perfomance and long life of the generator NorthStar is constantly improving its products The specifications outlined herein are subject to change without prior notice or obligation The purchaser and or user assumes liability of any modification and or alterations on this equipment from original design and manufacture Before using the user shall determine the suitability of this product for its intended use and assumes liability therein RULES FOR SAFE OPERATIONS Safety precautions are essential when operating this generator Respectful and cautious operation wil considerably lessen the possibilities of a personal injury This ma
3. 165936 References 5 Sight Glass Fill gear box until oil isin the middle of the glass Reference 6 Fan Vents Never block the vent slots or insert objects through the slots The closest object should be at least 3 feet away from the vents Reference 7 Mounting Holes Use these four locations to mount the generator head in place with four 5 8 grade 5 bolts anchors see Installation section Reference 8 120V Receptacle This twistlock receptacle is a 120V 30A receptace National Electrical Manufacturers Association NEMA number L5 30R This receptacle accepts NEMA plug number L5 30P Reference 9 120V Receptacle The generator has a control panel with two 120V 20A straight blade receptacle duplexes two receptacles in a common housing NEMA numberis 5 20R Reference 10 Circuit Breaker Two 20A push to reset thermal circuit breakers Reference 11 Circuit Breaker One 30A push to reset thermal circuit breaker Reference 12 120 240V Receptacle This straight blade receptacle is 120 240V 60A This receptacle accepts a NEMA plug number 14 60P ALWAYS use grounded male plugs The neutral line of the generator is mechanically grounded to the frame Matching NEMA male plugs must always be used Reference 13 Gear Box Cast iron frame 1 7 gear ratio References 14 Warning Decals Read and follow all warnings Reference 15 Grounding Clamp Ground the generator via the grounding damp to a copper pipe or rod
4. MODEL 27500 PTOG ITEM 165937 Power Take Off Generator M165937D A WARNING Read this manual Serinus injury or death can result i satety instruct ons are not followed A DANGER Fire hazard Dp nal aperale in an enclosure or building Fire or exalosion will resull Never place this product near combustible materials A DANGER Breathing hazard Poisonous fumes from engine will kill you Do nel aperals Ne genaralor in anc osed areas Dp nel aperale genera or near bu Iding or nside of buildings Any Questions Comments or Problems Call Customer Service at 1 800 270 0810 Hours Monday Friday 7 30 AM to 5 30 PM Saturday 7 30 to 11 30 AM CST THANK YOU Thank you for purchasing a NorthStar Power Take Off Generator Your machine is designed for long life dependability and the top perfomance you demand Please take the time now to read through this manual so you can better understand the machine s operation maintenance and safety precautions Everyone who operates this generator must read and understand this manual The time you take now will prolong your generator s life and prepare you for its safe operation Enjoy the exceptional perfomance of your NorthStar PTO Generator IMPORTANT If this machine is used by anyone who isnot the owner oris loaned or rented make certain the operator Is instructed in safe and proper operation of this machine Reads and understands the manuals pertaining to this m
5. achine NOTICE K BAR Industries Incorporated reserves the right to make improvements in design and or changes in spedfications at any time without incurring any obligation to install them on units previously sold TABLE OF CONTENTS Thank you Specifications ANSI safety definitions Machine component identification Generator features Introduction Rules forsafe operation Installation Load application Pre start up preparations Generator care Troubleshooting SPECIFICATIONS Item Number 165937 Maximum Output 27500 Watts W Continuous Output 24000 W Voltage 120 240 Volt V Phase Single phase 4 wire Frequency 59 0 63 0 Hertz Hz Power Factor 1 0 Minimum PTO HP 48 HP at540 RPM Input Shaft 1 3 8 Diameter 6 spline 120V Receptacle 2 20 Amp A duplex NEMA 5 20R 30A Twistlock NEMA L5 30R 120 240V Receptacle 60A Straight blade NEMA 14 60R 100A Pin and sleeve 4100R12W Circuit Breaker 2 20Athermal push to reset style 30A thermal push to reset style 60A thermal magnetic 100A thermal magnetic Gear Box Gear Ratio I Gear Oil SAE 80W 90 Oil Capacity 53 Qt 5 L Dimensions Length 36 95 93 9 cm Width 16 85 42 8 cm Height 20 79 52 8 cm Gross Weight 425 lb 193 2 kg ANSI SAFETY DEFINITIONS DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury This signal word is to be limited to the most extreme situat
6. avy surge of current is required for only an instant the generator will not be damaged if it can bring the motor up to speed in a few seconds If difficulties in starting a motor are experienced turn off all other electrical loads and if possible reduce the load on the electric motor EXTENSION CORDS When electric power is to be provided to various loads at some distance from the generator extension cords can be used These cords should be sized to allow for distance in length and amperage so that the voltage drop between the set and point of use is held to aminimum Maximum Extension Cord Length Amps Load 10 12 14 at watts Ga Ga Ga 240V Cord Cord Cord 10 2400 250 150 100 Us 20 4800 125 75 50 25 30 7200 60 35 25 10 40 9600 30 15 10 50 12000 1s Not recommended CAUTION Equipment damage can result from the low voltage caused by using an extension cord wth a small wie size Use this chart to estimate the total load on your generator For Determining Generator Load Requirements Dev ice Running Watts Air Conditioner 12 000 Btu 1700 a Battery Charger 20 Amp 500 Belt Sander 3 1000 Chain Saw 1200 Circular Saw 6 1 2 900 Coffee Maker 1000 Compressor 1 HP 2000 a Compressor 3 4 HP 1800 a Compressor 1 2 HP 1400 a Curling lron 700 Dishwasher 1200 Edge Trimmer 500 Electric Nail Gun 1200 Electric Range one
7. e in the generator voltmeter is at or above the black line in the green area A load can now be applied to the generator Remember to stay clear of the rotating PTO driveline From the tractor seat re adjust the speed until the needle on the generator voltmeter is close to the black line in the green area If the needle will not ise to the green area no matter what the engine speed the generator is either overloaded or there is a_ problem Use the troubleshooting guide at the end of the manual for assistance with possible problems Before each use check the gear box oil level Use 80W 90 SAE synthetic gear oil and fill to the middle of the oil level sight plug LOAD APPLICATION Itis important to determine the total electrical load before itis connected to the generator The two major factors in determining the life of a generator head are heat build up caused by overloading the generator and corrosive contaminants that attack the wiring insulation If the generator is overloaded the wires become excessively hot and cause the insulation to break down reducng its ability to resist corrosive contaminants Over time the effectiveness of the insulation is eliminated and a dead short can result Always compare the generator nameplate data with that of the equipment to be used to ensure that watts volts amperage and frequency requirements are suitable for operating equipment The wattage listed on the equipment nameplate is its rated out
8. element 1500 Electric Skillet 1250 Freezer 800 b Furnace Fan 1 3 HP 1200 a Hair Dryer 1200 Hand Dill 1 1100 Hand Dail 1 2 875 Hand Diill 3 8 500 Hand Diill 1 4 250 Hedge Trimmer 450 Home Computer 150 Impact Wrench 500 Jet Pump 800 a Lawn Mower 1200 Light Bulb 100 Microwave Oven 700 Milk Cooler 1100 a Oil Burner on Furnace 300 Oil Fired Space Htr 140 000 Btu 400 Oil Fired Space Htr 85 000 Btu 225 Oil Fired Space Htr 30 000 Btu 150 Oven 4500 Paint Sprayer Airless 1 3 HP 600 a Paint Sprayer Airless handheld 150 Radio 200 Refrigerator 600 b Slow Cooker 200 Submersible Pump 1 1 2 HP 2800 a Submersible Pump 1 HP 2000 a Submersible Pump 1 2 HP 1500 a Sump Pump 600 a Table Saw 10 2000 a Television 500 Toaster 1000 Vacuum cleaner 250 VCR 70 Water Heater 3000 Weed Trimmer 500 a Hard starting motors require 3 to 5 times the rated running watts b These loads may require up to 15 minutes to restart due to its nomal build up of compressor head pressure NOTE For extremely hard to start loads such as air conditioners and air compressors consult the equipment dealer to determine the maximum wattage PRE START UP PREPARATIONS Your generator has been thoroughly tested priorto shipment from the factory However damage can occur during shipping so be sure to check for damaged parts loose or missing nuts and bolts If the these pr
9. erator RPM Hz voltage at 120V Output Receptade 0 3780 63 0 125V 50 3600 60 0 122V 100 3480 58 0 118V Output voltage should be checked periodically to ensure continued proper operation of the generating plant and appliances it can be checked with a portable meter Frequency can be checked by using an electric clock with a sweep second hand Timed against a wrist watch ora stop watch the clock should be correct within 2 seconds per minute All speed setting adjustments should be done by a qualified technician GENERATOR CARE The generator head is a two pole 3600 RPM 60 Hz brushless revolving field and synchronous type with two sealed radial bearings Proper care and maintenance are necessary to ensure a long trouble free life Exercising The Generator The generator should be operated every four weeks This is accomplished by starting the engine and applying a load for 15 minutes This will dry out any moisture that has accumulated in the windings If left this moisture can cause corrosion in the winding Frequent operation of the generator wil also ensure that the set is operating properly should it be needed in an emergency Generator Maintenance The generator head is brushless and maintenance free Any major generator service including the installation or replacement of parts should be performed only by a qualified electrical service technician USE ONLY NorthStar APPROVED REPAIR PARTS AVAILABLE AT 1 800 270
10. fective capacitor Defective circuit breaker Engine speed too slow PTO not engaged Gear box is malfunctioning Defective bearing Defective gear No orlow gear oil PTO driveline is operating at an angle of greater than 15 e Unsynchronized PTO driveline Possible Remedies a Increase tractor RPMs b Reduce the load See Load Application section of this manual a Disconnectload b Replace receptacle c Reduce the load See Load Application section of this manual d Contact Customer Senice for the nearest service center a Contact Customer Senice for the nearest service center a Reduce the load See Load Application section of this manual b Make sure there is atleast 3 feet of clearance on all sides of generator Disconnectload b Replace wire Replace receptacle d Contact Customer Senice for the nearest service center e Contact Customer Senice for the nearest service center f Contact Customer Senice for the nearest service center g Contact Customer Senice for the nearest service center h Increase tractor RPMs I Engage PTO j Contact Customer Service for the nearest service center a Contact Customer Service for the nearest service center b Contact Customer Service for the nearest service center c Fill gear box to oil level sight d Reposition the tractor or generator so the angle is reduced to less than 15 both vertically and horizontally e Disassemble PTO d
11. he following chart shows the approximate current required to start and run various types and sizes of 120 volt 60 cycle electric motors under various conditions 120V 60 Hz Motors Starting Amps Watts 1 6 525 7 11 9 18 16 22 1 4 700 9 15 12 23 22 32 1 3 875 11 18 14 29 26 35 1 2 1175 15 25 20 40 NA 1 1925 24 40 3264 NA 11 2 3 4075 51 85 68 136 NA 5 6750 84 140 112 224 NA l2 2400 30 50 40 80 NA 2900 36 60 48 96 NA The figures given above are for an average load such as a blower or fan If the electric motor is connected to a hard starting load such as an air compressor it will require more starting current If itis connected to a light load or no load such as a power saw it will require less starting current The exact requirement will also vary with the brand or design of the motor Generators respond to severe overoading differently than the power line When overloaded the engine is not able to supply enough power to bring the electric motor up to operating speed The generator responds to the high initial starting current but the engine speed drops sharply The overload may stall the engine If allowed to operate at very low speeds the electric motor starter winding will burn out in a short time The generator head winding might also be damaged Running the generator under these conditions may result in damage to the generator stator as well as the electric motor windings Because the he
12. ions WARNING indicates a potentially hazardous situation which if not avoided could resultin a death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided may resultin minor or moderate injury It may also be used to alert against unsafe practices MACHINE COMPONENT IDENTIFICATION Figure 1 Ref 1 12 ii Ref Rei VeSUPUvll 1 Voltmeter 11 30A Circuit Breaker 2 Lifting Eye 12 120 240V 60A Receptacle 3 Breather Oil Fill Plug 13 Gear Box 4 1 3 8 6 Spline Input Shaft 14 Warning Decals 5 Sight Glass 15 Grounding Clamp 6 Fan Vents 16 100A Circuit Breaker 7 Mounting Holes 17 120 240V 100A Pin and Sleeve 8 120V 30A Twistlock Receptacle 18 60A Circuit Breaker 9 120V 20A Duplex Receptacles 19 Shield 10 20A Circuit Breakers References 1 Voltmeter 441 ter needle GENERATOR FEATURES should be in green area during al generator load conditions The black line in the center on the green 3 Figure 2 Ref 13 19 area indicates 120V Duting no load conditions the needle should be at or above the black line References 2 Lifting Eye Use when lifting or moving generator Reference 3 Breather Oil Fill Plug Use SAE 90 gearoil Maintain the correct oil level Over filling can cause the oil to over heat and damage seals and bearings References 4 1 3 8 Diameter 6 Spline Input Shaft 540 RPM PTO driveline is available from Norther Item
13. nual will warn of specific personal injury potential and these will be designated by the symbol A WARNING This generator is equipped with a grounding damp located on the generator frame for your protection Always complete the grounding path from the generator to a copper pipe rod that is driven into moist earth to prevent electrical shock ALWAYS use electrical cords that are in good condition Worn bare frayed or otherwise damaged cords can cause electric shock ALWAYS use a ground fault circuit interrupter GFCI in damp or highly electrical conductive areas and on construction job sites to prevent electric shock ALWAYS remove PTO driveline before working on the generator ALWAYS provide adequate ventilation Do not operate generator in any enclosed or narrow space Engines consume oxygen and give off deadly carbon monoxide a poisonous gas Improper ventilation wil cause damage to generator and possible injury to people ALWAYS remove all oil or gasoline deposits and accumulated dirt from generator and immediate area Keep generatorhead and engine clean ALWAYS wear ear protection while operating generator ALWAYS keep area around generator clean NEVER operate the generator without proper guarding NEVER operate the generator continuously when PTO driveline is at angle greater than 15 both horizontally and vertically NEVER operate the generator while wearing loose fitting dothing such as neckties scarves or un
14. oblems occur call Customer Service at 1 800 270 0810 GROUNDING All units must be grounded Drive a 3 4 or 1 copper pipe or rod into the ground close to the generator The pipe od must penetrate moist earth Connect an approved ground clamp to the pipe Run a 8 gauge wire from the damp to the generator ground screw Do not connect to a water pipe or a ground used bya radio system OPERATING SPEED The generator must be run at the correct speed in order to produce the proper electrical voltage and frequency The output voltage should be checked to ensure the generator is working properly subsequent to connecting a load to the generator Failure to do so could result in damage to equipment plugged into the unit and possible injury to the individual All engines have a tendency to slow down when a load is applied When the electrical load is connected to the generator the engine is more heavily loaded and as a result the speed drops slightly This slight decrease in speed together wth the voltage drop within the generator itself results in a slightly lower voltage when the generator is loaded to its full capacity than when it is running wth no load The slight variation has no appreciable effect in the operation of motors lights and most appliances Electronic equipment and clocks will be effected if correct RPM is not maintained See Load vs Output chart Load Output SC Percent of Speed Frequency Generator Gen
15. put However some equipment may require three to ten times more wattage than its rating on the nameplate as the wattage is influenced by the equipment efficiency power factor and starting system NOTE If wattage is not given on equipment nameplate approximate wattage may be determined by multiplying nameplate voltage by nameplate amperage VOLTS X AMPS WATTS Example 120V X5A 600W When connecting a resistive load such as incandescent lights heaters or common electric power tools a capacity of up to the generator full rated wattage output can be used When connecting a resistive inductive load such as a fluorescent or mercury light transformers or inductive coils a capadty of up to 0 6 times the generator s full rated output can be used Always allow the generator to reach operating speed before a load is applied STARTING ELECTRIC MOTORS Electric motors require much more current amps to start than to run Some motors particularly low cost split pbhase motors are very hard to start and require 5 to 7 times more currentto start than to run Capacitor motors are easier to start and usually require 2 to 4 times as much current to start than to run Repulsion Induction motors are the easiest to start and require 1 5 to 2 5 times as much to start than to run Most fractional motors take about the same amount of current to run them whether they are of Repulsion Induction RI Capacitor Cap or Split Phase SP type T
16. riveline and reassemble with CV joints synchronized
17. te must be free from water moisture or dust Foreign matters such as dust dirt sand lint or abrasive materials can cause damage if allowed inside the generator All electrical components should be protected from excessive moisture or the insulation system wil deteriorate and result in grounding or shorting out of the generating system Design the application to minimize the angle of the driveline 15 maximum The smaller the angle of operation the longer the driveline will last When trailer mounting the generator select a trailer that is wide enough to withstand the torque of start up and loading toque Wheels that are not spaced propery could cause the trailer to tip over The constant vibration of the generator can cause metal fatigue of the trailer base if the steel used is not thick enough DANGER Trailer may tip over and cause serious injury or death Never stand near an operating PTO generator Use four grade 5 5 8 bolts to mount generator After the generator is firmly mounted attach the PTO driveline to the generator then the tractor Use a synchronized PTO driveline rated at 48 HP minimum DANGER Never attach PTO driveline while tractor is running DANGER Always have proper guarding of rotating parts Failure to guard the power transmission mechanisms may result in serious injury or death While seated on the tractor and the engine at idle engage the PTO Slowly increase the throttle 90506 needl
18. tucked shirts NEVER operate the generator or handle any electrical equipment while standing in water while barefoot while hands are wet or while in the rain or snow Electric shock may result NEVER operate the generator under the following conditions A Excessive change in engine speed slow or fast Overheating inload connecting devices Sparking orarcs from generator Loss of electrical output Damaged receptacles Engine misfire Excessive vibration Encdosed compartments or confined areas Flame or smoke Rain snow or wet conditions Operator non attendance Without proper guarding in place TASTTOMNMVOW WARNING Keep fire extinguisher dose by your generator and be familiar with how to use it Consult your local fire department for correct extinguisher type DANGER Remember exhaust fumes are deadly carbon monoxide a poisonous gas and must be vented to the outside where there are no people Cooling air of sufficient amounts must be brought in and exhausted out to ensure proper cooling of the engine and generator INSTALLATION Choose a location where the generator will not be exposed to rain snow or direct sunlight Common places for mounting your PTO generator are to a trailer ora cement slab However you choose to mount the generator make sure it can get as close to the load as possible This will make using the generator more convenient and reduce voltage diop The installation si
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